Thermal spreading for an externally pluggable electronic module

ABSTRACT

A cooling apparatus for dissipating heat from an electronic module is disclosed. The cooling apparatus may include a thermally conductive shell having a surface in contact with, and configured to conduct heat away from, the module. The apparatus may also include an electrically insulative layer positioned between, and configured to conduct heat from, the module to the shell. The apparatus may also include an electrical cord, attached to the module that contains a thermally conductive layer in thermally conductive contact with the shell that is configured to conduct heat away from the shell. The apparatus may also include an electrically insulative layer between the thermally conductive layer and an electrical conductor within the electrical cord. The apparatus may also include an electrically insulative layer, positioned between the thermally conductive layer and an electrical cord outer surface, configured to convectively dissipate heat from the thermally conductive layer.

BACKGROUND

The present disclosure generally relates to cooling a heat-producingelectronic module. In particular, this disclosure relates to thermalspreading of heat to an electrical cord attached to an externallypluggable heat-producing electronic module.

A heat sink may be used in computers and electronic systems as a passiveheat exchanger, and may act as a reservoir that can absorb an arbitraryamount of heat without significantly changing temperature. Heat sinksmay be used in computers, for example, to cool devices such as centralprocessing units (CPUs) and/or graphics processing units (GPUs).

A heat sink may also dissipate heat produced by electronic devices intoa medium, such as air, water, or a coolant/refrigerant. Heat sinks mayreach a temperature greater than a cooling medium, in order to transferheat across a thermal gradient from an electronic device to the medium,by convection, radiation, or conduction.

A thermal interface material (TIM) may be used to enhance heat transferbetween an electronic device, such as an integrated circuit (IC), and aheat sink, and may be fabricated from thermally conductive material. ATIM may increase thermal conductivity by filling irregularities and airgaps between adjacent, mating surfaces (e.g., of the IC and the heatsink) with a thermally conductive material.

SUMMARY

Various aspects of the present disclosure may be useful for improvingheat spreading and dissipation for an externally pluggableheat-producing electronic module. A heat-producing electronic moduleconfigured according to embodiments of the present disclosure may haveenhanced reliability, as a result of lower operating temperatures,relative to a module without improved heat spreading capability.

Embodiments may be directed towards a cooling apparatus for dissipatingheat from a heat-producing electronic module. The cooling apparatus mayinclude a thermally conductive shell having at least one surface inthermally conductive contact with the heat-producing electronic module,and configured to conduct heat away from the heat-producing electronicmodule. The cooling apparatus may also include a first electricallyinsulative layer, positioned between the at least one surface of thethermally conductive shell and the heat-producing electronic module andconfigured to conduct heat from the heat-producing electronic module tothe thermally conductive shell. The cooling apparatus may also includean electrical cord attached to the heat-producing electronic module andcontaining a thermally conductive layer in thermally conductive contactwith the thermally conductive shell, the thermally conductive layerconfigured to conduct heat away from the thermally conductive shell. Thecooling apparatus may also include a second electrically insulativelayer, positioned between the thermally conductive layer and at leastone electrical conductor within the electrical cord and a thirdelectrically insulative layer, positioned between the thermallyconductive layer and an outer surface of the electrical cord, andconfigured to convectively dissipate heat from the thermally conductivelayer.

Embodiments may also be directed towards a system for dissipating heatfrom a heat-producing electronic module. The system may include achassis having at least one receptacle configured to receive aheat-producing electronic module, a heat-producing electronic moduleinserted into a receptacle of the at least one receptacle and a coolingapparatus configured to dissipate heat from the heat-producingelectronic module. The cooling apparatus may include a thermallyconductive shell in thermally conductive contact with the heat-producingelectronic module, and configured to conduct heat away from theheat-producing electronic module. The cooling apparatus may also includea first electrically insulative layer, positioned between the at leastone surface of the thermally conductive shell and the heat-producingelectronic module and configured to conduct heat from the heat-producingelectronic module to the thermally conductive shell. The coolingapparatus may also include a first thermally conductive electrical cordattached to the heat-producing electronic module and containing athermally conductive layer in thermally conductive contact with thethermally conductive shell, the thermally conductive layer configured toconduct heat away from the thermally conductive shell. The coolingapparatus may also include a second electrically insulative layer,positioned between the thermally conductive layer and at least oneelectrical conductor within the first thermally conductive electricalcord and a third electrically insulative layer, positioned between thethermally conductive layer and an outer surface of the first thermallyconductive electrical cord, and configured to convectively dissipateheat from the thermally conductive layer. The system may also include afan operable to dissipate heat from the thermally conductive layer ofthe cooling apparatus by flowing cooling air across the first thermallyconductive electrical cord attached to the heat-producing electronicmodule.

Embodiments may also be directed towards a method for assembling acooling apparatus for dissipating heat from a heat-producing electronicmodule. The method may include attaching an electrically insulativelayer to at least one interior surface of a thermally conductive shelland attaching a thermally conductive layer of a thermally conductiveelectrical cord to the thermally conductive shell. The method may alsoinclude inserting, to form a thermally conductive interface between anouter surface of the heat-producing electronic module and an interiorsurface of the thermally conductive shell, the heat-producing electronicmodule into the thermally conductive shell.

Aspects of the various embodiments may be used to enable enhancedperformance and/or power dissipation of pluggable electronic modules.Aspects of embodiments may also be useful for lowering the operatingtemperature of an electronic system chassis, and providing increasedelectromagnetic interference (EMI) shielding within an electrical cordconnected to an externally pluggable electronic module. Aspects of thevarious embodiments may also be useful for providing cost-effectivecooling apparatuses for use with heat-producing electronic modules, byusing existing and proven design, fabrication, assembly and thermalinterface material (TIM) technologies.

The above summary is not intended to describe each illustratedembodiment or every implementation of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings included in the present application are incorporated into,and form part of, the specification. They illustrate embodiments of thepresent disclosure and, along with the description, serve to explain theprinciples of the disclosure. The drawings are only illustrative ofcertain embodiments and do not limit the disclosure.

FIG. 1 is a cross-sectional drawing depicting an apparatus for coolingan externally pluggable heat-producing electronic module, according toembodiments of the present disclosure.

FIG. 2 is a flow diagram of a method of assembling an apparatus forcooling an externally pluggable heat-producing electronic module,according to embodiments consistent with FIG. 1.

FIG. 3 includes four cross-sectional drawings depicting a sequence ofsteps for assembling an apparatus for cooling an externally pluggableheat-producing electronic module, according to embodiments consistentwith FIG. 1, 2.

While the invention is amenable to various modifications and alternativeforms, specifics thereof have been shown by way of example in thedrawings and will be described in detail. It should be understood,however, that the intention is not to limit the invention to theparticular embodiments described. On the contrary, the intention is tocover all modifications, equivalents, and alternatives falling withinthe spirit and scope of the invention.

In the drawings and the Detailed Description, like numbers generallyrefer to like components, parts, steps, and processes.

DETAILED DESCRIPTION

Certain embodiments of the present disclosure can be appreciated in thecontext of providing thermal spreading for cooling externally pluggableelectronic modules such as optoelectronic interface devices or modules.Optoelectronic modules may be used to reversibly convert betweenelectrical and optical modes of signal transmission, and may be usefulto enable optical data transmission, for example, between computersand/or data communication networks. While not necessarily limitedthereto, embodiments discussed in this context can facilitate anunderstanding of various aspects of the disclosure. Certain embodimentsmay also be directed towards other equipment and associatedapplications, such as providing thermal spreading for cooling chargingcables for portable devices. Device charging cables may contain active(heat-producing) electronics, and may be useful for charging a widevariety of portable electronic devices such as cell phones, personaldigital assistants (PDAs), laptops and pagers.

Embodiments may also be directed towards providing thermal spreading forcooling cable assemblies including signal boosters and re-drive devices.Such cable assemblies may contain active electronic (heat-producing)devices used to repower or drive signals over a longer cable length thanwould be practical for signals that were not actively re-driven.

For ease of discussion, it may be understood that the terms “electronicmodule”, “heat-producing electronic module”, “electronic device” and“heat-producing electronic device” may be used interchangeably herein,in reference to an electronic apparatus or assembly which may generateheat during its operation.

A heat-producing electronic module such as an optoelectronic module orother electronic module, device, or assembly that is externallypluggable into a chassis, may be cooled by flowing cooling air over themodule to limit its operating temperature. Limiting a heat-producingelectronic module's operating temperature to a specified range may allowit to operate stably and reliably for the duration of a specifiedoperating life.

In certain applications, flowing cooling air over the heat-producingelectronic module may not sufficiently limit the module's operatingtemperature within the specified operating range. A heat sink locatedwithin the chassis and thermally coupled to the heat-producingelectronic module through a thermally conductive module housing may beused for the removal and dissipation of heat from the heat-producingmodule.

A thermally conductive path between the heat-producing electronic moduleand a heat sink may include a mating interface between the thermallyconductive housing and a corresponding receptacle within the chassis. Incertain applications, this mating interface may not include a thermalinterface material (TIM). Each element in the thermally conductive path(e.g., the thermally conductive housing, receptacle, and matinginterfaces) may offer thermal resistance to heat flowing from theheat-producing electronic module to the heat sink. Thermal resistancemay, in turn, may limit heat removal from the heat-producing electronicmodule and may limit the maximum power and performance of the electronicmodule.

According to embodiments of the present disclosure, a cooling apparatusmay include a thermally conductive shell in thermally conductive(physical) contact with a heat-producing electronic module. Thethermally conductive shell may also be in thermally conductive contactwith a thermally conductive layer of an electrical cord that is attachedto the module. The cooling apparatus may be useful to conduct heat awayfrom the heat-producing electronic module to the thermally conductivelayer of the electrical cord, where it may be dissipated by cooling airflowing over the cord.

In certain embodiments, efficient heat transfer away from aheat-producing electronic module can be useful for providing a desiredmodule operating temperature range and increased electronic device andsystem reliability. In embodiments, efficient heat removal from anelectronic module may allow the module to dissipate an increased amountof heat, which may, for example, allow the module to be operated at ahigher frequency and yield higher module and/or system performance,relative to a module having less efficient heat removal. For example, aheat-producing electronic module with inefficient heat removal may beable to dissipate approximately 2 Watts (W), while a heat-producingelectronic module with efficient heat removal (increased heat spreadingthrough the use of a thermally conductive shell) may be able todissipate approximately 5 W.

A cooling apparatus according to embodiments may be configured to fitwithin the dimensions of, and be compatible with, an existing thermallyconductive housing. A cooling apparatus according to embodiments may bea cost-effective, thermally efficient device for cooling externallypluggable electronic modules.

For the purpose of this application, materials referred to as “thermallyconductive” which are also electrically conductive may generally have athermal conductivity greater than 100 W/m*K. Such materials may includemetals such as aluminum, copper, brass and nickel. Other materials, suchas carbon fiber, graphite and graphene may have different ranges ofthermal conductivities.

The following table lists, by way of example, some materials which maybe useful in the construction of an electronic module cooling apparatus.

TABLE 1 Thermal Conductivity Values Thermal conductivity Material (W/m *K range) Aluminum 204-250 Copper 350-401 Carbon fiber (electricallyinsulative)  21-180 Graphite  300-1500 Graphene 5020 (theoretical)Electrically insulative plastic and .01-60  polymer materials including:Nylon 66 Kapton tape Liquid Crystal Polymers (LCP) AcrylonitrileButadiene Styrene (ABS) Polycarbonate-ABS (PC/ABS) Polyphenylene Sulfide(PPS) Crystalline Thermoplastics

Certain embodiments relate to efficient transfer of heat away from aheat-producing electronic module to a thermally conductive electricalcord attached to the module. FIG. 1 is a cross-sectional drawing 100depicting an apparatus for cooling an externally pluggableheat-producing electronic module 118, according to embodiments of thepresent disclosure. The apparatus may include a thermally conductiveshell 104 in thermally conductive contact with the heat-producingelectronic module 118 and in thermally conductive contact with athermally conductive layer 110 of attached electrical cord 116.

The apparatus may be useful for conducting heat away from theheat-producing electronic module 118, through the thermally conductiveshell 104 and into the thermally conductive layer 110 of attachedelectrical cord 116, where it may be dissipated. In certain embodiments,airflow in certain embodiments, airflow from chassis 122 is directedover, and enhances the heat dissipation from, electrical cord 116. Incertain embodiments, the apparatus may include a single electrical cord116 thermally coupled to the heat-producing electronic module 118. Incertain embodiments, the apparatus may include two or more electricalcords 116 thermally coupled to the heat-producing electronic module 118.

In embodiments, thermally conductive shell 104 may have at least oneinterior surface in thermally conductive contact with, and may be usefulto conduct heat away from, the heat-producing electronic module 118. Incertain embodiments, thermally conductive shell 104 may be fabricatedfrom aluminum or metal alloys containing aluminum, and in certainembodiments, thermally conductive shell 104 may be fabricated fromcopper or metal alloys containing copper.

A first electrically insulative layer 130 is depicted as positionedbetween at least one interior surface of the thermally conductive shell104 and at least one surface of the heat-producing electronic module118, and may be useful to conduct heat from the heat-producingelectronic module 118 to the thermally conductive shell 104. Firstelectrically insulative layer 130 can be useful for insulatingheat-producing electronic module 118 from electrical hazards, such aselectrostatic discharge (ESD) events, which may be introduced toelectrical cord 116.

Electrically insulative layer 130 can include materials such as mica,Kapton tape, or a thermal interface material (TIM), or otherelectrically insulative materials listed in Table 1. Electricallyinsulative layer 130 may be self-adhesive, or attached to a surface ofthermally conductive shell 104 through the use of commercially availableadhesive products.

In certain embodiments, the heat-producing electronic module 118 may bean optoelectronic module, which may be useful for converting betweenelectrical and optical modes of signal transmission. In certainembodiments, the optoelectronic module may be a “100 Gb/s form factorpluggable” (CXP) module. A CXP module may include electro-opticaldevices which may be sensitive to operating temperatures aboveapproximately 50° C. In embodiments, an electronic module coolingapparatus may be useful for limiting and operating temperature for aheat-producing electronic module such as a CXP module.

In embodiments, an electrical cord 116 having a thermally conductivelayer 110 may be attached to heat-producing electronic module 118.Thermally conductive layer 110 may be in thermally conductive contactwith thermally conductive shell 104, and may be useful for conductingheat generated by heat-producing electronic module 118 away fromthermally conductive shell 104, where it may be dissipated. In certainembodiments, thermally conductive layer 110 may include a layer ofbraided metal wires, for example, copper, nickel-plated copper, oraluminum wires. In certain embodiments, thermally conductive layer 110may include a metallic foil, and in certain embodiments thermallyconductive layer 110 may include a carbon fiber material. In embodimentshaving a thermally conductive layer 110 that is also electricallyconductive (e.g., a layer of braided metal wires or metallic foil),layer 110 may be useful in providing electromagnetic interference (EMI)shielding for electrical conductors 124A, 124B (view 150). Such EMIshielding may both attenuate electrical emissions resulting from signalson electrical conductors 124A, 124B, and may also shield electricalconductors 124A, 124B from receiving electromagnetic interference fromexternal sources, such as an adjacent cable or other radiating element.

Electrical cord core 114 (view 100) may include electrical conductors124A, 124B (view 150) and insulative layers 128A, 128B (view 150).Electrical conductors 124A, 124B (view 150) of electrical cord 116 maybe attached to heat-producing electronic module 118 and may be usefulfor electrically connecting electrically module 118, through electricalcord 116, to another electronic module, device, or system. In certainembodiments, electrical conductors 124A, 124B (view 150) may beconfigured to conduct power or “single-ended” signals, and in certainembodiments electrical conductors 124A, 124B may be configured in pairsto conduct differential signals. View 150 depicts two electricalconductors (124A, 124B), however embodiments may include a differentnumber of electrical conductors suitable to provide electricalinterconnect to heat-producing electronic module 118. In certainembodiments, insulative layers 128A, 128B (view 150) may surroundelectrical conductors 124A, 124B (view 150). In certain embodiments,electrical cord core 114 (view 100) may include one or more opticalfibers which may be useful to conduct optical signals to or from aheat-producing electronic module 118.

In certain embodiments, a second electrically insulative layer 112 maybe positioned between the at least one electrical conductor (e.g., 124A,124B, view 150) and thermally conductive layer 110 within the electricalcord 116. Second electrically insulative layer 112 may abut firstelectrically insulative layer 130 to form a continuous electricallyinsulative layer from the thermally conductive shell 104 extending intothe attached electrical cord 116. In certain embodiments that include anthermally and electrically conductive layer 110, second electricallyinsulative layer 112 may be useful for electrically insulatingconductors 124A, 124B, (view 150) from layer 110.

In embodiments, a third electrically insulative layer 108 may be formedbetween the thermally conductive layer 110 and an outer surface of theelectrical cord 116. Electrically insulative layer 108 can be athermally conductive and relatively flexible material and may be usefulfor convectively dissipating heat transferred from the thermallyconductive layer 110 to an outer surface of electrical cord 116. Inembodiments, a thickness and surface contour or texture of electricallyinsulative layer 108 may be specified to promote heat dissipation fromthe outer surface of electrical cord 116. For example, a layer 108thickness of 3 mm combined with ridges or grooves formed on the outersurface of layer 108 may increase the thermal dissipation capability ofelectrical cord 116, relative to an electrical cord having a thickerlayer 108 having no surface irregularities. In certain embodimentshaving a thermally conductive layer 110 that is also electricallyconductive, electrically insulative layer 108 may be useful forpreventing electrical (e.g., ESD) events from being conducted throughlayer 110 to thermally conductive shell 104 and/or heat-producingelectronic module 118. In certain embodiments having a thermallyconductive layer 110 that is electrically insulative, third electricallyinsulative layer 108 may be optional.

In certain embodiments, an electronic module cooling apparatus mayinclude a thermally conductive housing 120 that at least partiallyencloses and is in thermally conductive contact with the heat-producingelectronic module 118. Thermally conductive housing 120 may be insertedinto a receptacle 106 within chassis 122 and may provide a supplementalthermal path for transferring a portion of the heat generated byheat-producing electronic module 118 to a heat sink 102. Heat sink 102,located within electronic equipment chassis 122, may dissipate a portionof the heat generated by heat-producing electronic module 118. Inembodiments, housing 120 may be constructed from sheet metal, or otherthermally conductive material.

In certain embodiments, the combination of thermally conductive shell104 and thermally conductive layer 110 may create a more efficientthermal path than the combination of thermally conductive housing 120and receptacle 106 to the heat sink 102. The relative thermalconductivity of the two described paths may be affected by the thermalconductivity of interfaces and materials within the paths. For example,thermally conductive shell 104 may be connected to thermally conductivelayer 110 of attached electrical cord 116 by a thermally robust processsuch as crimping or soldering or through the use of a TIM. In contrast,in certain applications, thermally conductive housing 120, receptacle106 and heat sink 102 may be attached to each other less effectivethermal interfaces such as a dry surface contact. In particularembodiments, thermally conductive housing 120 may be constructed from amaterial having relatively low thermal conductivity such as rolledsteel.

Receptacle 106 may include electrical connectors designed to mate withelectrical connectors of heat producing electronic module 118, which maybe useful for conducting electrical signals between heat producingelectronic module 118 and other electrical equipment located withinchassis 122. In certain embodiments, chassis 122 may be, for example, aserver or electronic system that includes a plurality of receptacles 106configured to receive a plurality of thermally conductive housings 120.Thermally conductive housings 120 may include CXP or otheroptoelectronic modules used to interface signals transmitted overoptical fibers to the server or electronic system. CXP or otheroptoelectronic modules may electrically connect, for example, to acircuit board within the server or electronic system.

In embodiments, chassis 122 may include one or more fans operable toflow cooling air over externally plugged heat-producing electronicmodule 118 and attached cord(s) 116, which may be useful in dissipatingheat from the thermally conductive layer 110 of the electrical cord 116.Chassis 122 may also include vents or ports configured to direct thecooling airflow over attached cord(s) 116.

FIG. 2 is a flow diagram 200 illustrating a method for assembling acooling apparatus useful for dissipating heat from an externallypluggable heat-producing electronic module (118, FIG. 1). The coolingapparatus may establish a thermally conductive path between theheat-producing electronic module (118, FIG. 1) and a thermallyconductive electrical cord (116, FIG. 1) attached to the module (118,FIG. 1), according to embodiments consistent with FIG. 1. The method forassembling a cooling apparatus 200 may be useful for creating a coolingapparatus to efficiently transfer heat away from a heat-producingelectronic module. The process 200 moves from start 202 to operation204.

Operation 204 generally refers to attaching an electrically insulativelayer to at least one interior surface of a thermally conductive shell,which may correspond to the view provided by 325 (FIG. 3) and itsassociated description. Attachment of an electrically insulative layermay be useful in protecting a heat-producing electronic module from ESDor other electrical events. Once the electrically insulative layer isattached, the process moves to operation 206.

Operation 206 generally refers to attaching a thermally conductive layerof a first electrical cord to the thermally conductive shell, which maycorrespond to the view provided by 350 (FIG. 3) and its associateddescription. Attaching a thermally conductive layer of an electricalcord to the thermally conductive shell may be useful for creating athermal path from the shell to the cord. In certain embodiments, athermally conductive layer of a second electrical cord may be attachedto the thermally conductive shell. Once the thermally conductive layerof an electrical cord is attached to the thermally conductive shell, theprocess moves to operation 208.

Operation 208 generally refers to applying a thermally conductivecompound to at least one outer surface of the heat-producing electronicmodule and/or to at least one interior surface of the thermallyconductive shell, which may correspond to the view provided by 350 (FIG.3) and its associated description. A thermally conductive compound canbe used to enhance thermal conductivity between two mating surfaces(e.g., of the heat-producing electronic module and the conductive shell)by filling in irregularities on the surfaces. Once the thermallyconductive compound is applied, the process moves to operation 210.

Operation 210 generally refers to inserting the heat-producingelectronic module into the thermally conductive shell to form athermally conductive interface between at least one outer surface of theheat-producing electronic module and at least one interior surface ofthe thermally conductive shell, which may correspond to the viewprovided by 375 (FIG. 3) and its associated description. Inserting theheat-producing electronic module into the shell may also includeattaching the module to conductors within electrical cord 116. Once theheat-producing electronic module inserted into the thermally conductiveshell, the process moves to operation 212.

Operation 212 generally refers to inserting the heat-producingelectronic module and the thermally conductive shell into a thermallyconductive housing, which may correspond to the view provided by 375(FIG. 3) and its associated description. Inserting the heat-producingelectronic module and the thermally conductive shell into a thermallyconductive housing may provide a thermal path from the thermallyconductive shell, through the thermally conductive housing, to a heatsink mounted on a housing receptacle within a chassis. This thermallyconductive path may be useful in dissipating a portion of heat generatedby the heat-producing electronic module 118 (FIG. 1). The thermallyconductive housing may be inserted into a mating receptacle within achassis of an electronic system to establish electrical connections tothe heat-producing electronic module. Once the heat-producing electronicmodule and the thermally conductive shell are inserted into a thermallyconductive housing, the process 200 may end at block 214.

FIG. 3 includes four cross-sectional views 300, 325, 350 and 375depicting a method for assembling an apparatus configured to cool aheat-producing electronic module 118, according to embodimentsconsistent with FIGS. 1 and 2. The four views 300, 325, 350 and 375 maybe useful in illustrating details involved in creating a coolingapparatus assembly that has a highly conductive thermal path between aheat-producing electronic module 118 and a thermally conductive layer110 of an attached electrical cord 116. The views may be useful inillustrating steps used in creating a cooling apparatus configured todissipate heat generated by the heat-producing electronic module 118.

View 300 depicts a thermally conductive shell 104, designed to at leastpartially enclose a heat-producing electronic module 118, and maintainthermally conductive contact between the heat-producing electronicmodule 118 and at least one interior surface of the thermally conductiveshell 104. In certain embodiments, the thermally conductive shell 104may be designed to have a plurality of surfaces in thermally conductivecontact with heat-producing electronic module 118, and to fit within theinterior of an existing thermally conductive housing 120. In certainembodiments, thermally conductive shell 104 may be designed to encloseouter surface areas of heat-producing electronic module 118 havingparticularly high heat densities.

View 325 depicts the results of attaching a first electricallyinsulative layer 130 to at least one interior surface of the thermallyconductive shell 104. A first electrically insulative layer 130 such asmica, or an electrically insulative thermal interface material (TIM) maybe attached to interior surfaces of the thermally conductive shell 104to protect the heat-producing electronic module 118 from exposure toelectrostatic discharge (ESD) or other electrical events. Heat-producingelectronic module 118 may be, for example, an optoelectronic modulewhich may be sensitive to ESD events. ESD or other electrical events maybe introduced to the thermally conductive shell 104, for example,through an electrical connection of the shell 104 to an attachedelectrical cord 116.

Electrically insulative layer 130 may be attached to thermallyconductive shell 104 by the use of a commercially available adhesive orself-adhesive layer. Electrically insulative layer 130 may be chosen tohave a high thermal conductivity in order to facilitate the transfer ofheat from heat-producing electronic module 118 to thermally conductiveshell 104. The thickness of electrically insulative layer 130 may bechosen, in conjunction with the interior dimensions of thermallyconductive shell 104, in order to accommodate the insertion ofheat-producing electronic module 118 within the thermally conductiveshell 104.

View 350 depicts the results of attaching a thermally conductive layer110 of an electrical cord 116 to the thermally conductive shell 104.Creating a thermally conductive attachment between shell 104 andthermally conductive layer 110 of electrical cord 116 may be useful increating a path for conducting heat away from heat-producing electronicmodule 118 into electrical cord 116, where it may be dissipated.

In certain embodiments, attaching layer 110 to shell 104 may include asoldering process, and in certain embodiments, attaching layer 110 toshell 104 may involve a crimping process. In certain embodiments,attaching layer 110 to shell 104 may involve application of an adhesiveTIM to bond the thermally conductive layer 110 to the thermallyconductive shell 104.

Thermally conductive and dissipative cord 116 may be created by forminga second electrically insulative layer 112 on an outer surface of atleast one electrical conductor (124A, 124B, FIG. 1), attaching athermally conductive layer 110 to an outer surface of the secondelectrically insulative layer 112, and forming a third electricallyinsulative layer 108 on an outer surface of the thermally conductivelayer 110.

View 375 depicts the results of inserting the heat-producing electronicmodule 118 into the thermally conductive shell 104 to form a thermallyconductive interface between at least one outer surface of the module118 and at least one interior surface of the thermally conductive shell104. A thermally conductive interface created between the module 118 andthe thermally conductive shell 104 may be useful in providing a path forconducting heat generated by the module 118 to the thermally conductivelayer 110 of electrical cord 116.

In certain embodiments, a layer of thermally conductive compound (e.g.,thermal grease or TIM) may be applied to either an outer surface of theheat-producing electronic module 118 and/or an interior surface of thethermally conductive shell 104 before inserting the module 118 into theshell 104. A thermally conductive compound may include materials such asa Shin-Etsu thermal grease, Bergquist gap pad, or an Indium TIM product.A thermally conductive compound may be useful to enhance thermalconductivity of a thermal interface between the module 118 and the shell104.

According to certain embodiments, view 375 may also depict the resultsof inserting the heat-producing electronic module 118 and the thermallyconductive shell 104 into a thermally conductive housing 120. Housing120 may be useful for mating the module 118 with a chassis and providinga supplemental thermal path for the dissipation of heat produced bymodule 118. In certain embodiments, the heat-producing electronic module118 and the thermally conductive shell 104 may be inserted into thethermally conductive housing 120 through the use of a press-fittechnique. In certain embodiments, the heat-producing electronic modulemay be held within the thermally conductive shell through the use offasteners such as screws or clips.

The descriptions of the various embodiments of the present disclosurehave been presented for purposes of illustration, but are not intendedto be exhaustive or limited to the embodiments disclosed. Manymodifications and variations will be apparent to those of ordinary skillin the art without departing from the scope and spirit of the describedembodiments. The terminology used herein was chosen to explain theprinciples of the embodiments, the practical application or technicalimprovement over technologies found in the marketplace, or to enableothers of ordinary skill in the art to understand the embodimentsdisclosed herein.

1. A cooling apparatus for dissipating heat from a heat-producingelectronic module, the cooling apparatus comprising: a thermallyconductive shell having at least one surface in thermally conductivecontact with the heat-producing electronic module, and configured toconduct heat away from the heat-producing electronic module; a firstelectrically insulative layer, positioned between the at least onesurface of the thermally conductive shell and the heat-producingelectronic module and configured to conduct heat from the heat-producingelectronic module to the thermally conductive shell; an electrical cordattached to the heat-producing electronic module and containing athermally conductive layer in thermally conductive contact with thethermally conductive shell, the thermally conductive layer configured toconduct heat away from the thermally conductive shell; a secondelectrically insulative layer, positioned between the thermallyconductive layer and at least one electrical conductor within theelectrical cord; and a third electrically insulative layer, positionedbetween the thermally conductive layer and an outer surface of theelectrical cord, and configured to convectively dissipate heat from thethermally conductive layer.
 2. The apparatus of claim 1, wherein theheat-producing electronic module is an optoelectronic module.
 3. Theapparatus of claim 2, wherein the optoelectronic module is a 100 Gb/sform factor pluggable (CXP) module.
 4. The apparatus of claim 1, whereinthe thermally conductive shell includes copper.
 5. The apparatus ofclaim 1, wherein the thermally conductive shell includes aluminum. 6.The apparatus of claim 1, wherein the first electrically insulativelayer includes mica.
 7. A system for dissipating heat from aheat-producing electronic module, the system comprising: a chassishaving at least one receptacle configured to receive a heat-producingelectronic module; a heat-producing electronic module inserted into areceptacle of the at least one receptacle; a cooling apparatusconfigured to dissipate heat from the heat-producing electronic module,the cooling apparatus having: a thermally conductive shell in thermallyconductive contact with the heat-producing electronic module, andconfigured to conduct heat away from the heat-producing electronicmodule; a first electrically insulative layer, positioned between the atleast one surface of the thermally conductive shell and theheat-producing electronic module and configured to conduct heat from theheat-producing electronic module to the thermally conductive shell; afirst thermally conductive electrical cord attached to theheat-producing electronic module and containing a thermally conductivelayer in thermally conductive contact with the thermally conductiveshell, the thermally conductive layer configured to conduct heat awayfrom the thermally conductive shell; a second electrically insulativelayer, positioned between the thermally conductive layer and at leastone electrical conductor within the first thermally conductiveelectrical cord; and a third electrically insulative layer, positionedbetween the thermally conductive layer and an outer surface of the firstthermally conductive electrical cord, and configured to convectivelydissipate heat from the thermally conductive layer; and a fan operableto dissipate heat from the thermally conductive layer of the coolingapparatus by flowing cooling air across the first thermally conductiveelectrical cord attached to the heat-producing electronic module.
 8. Thesystem of claim 7, wherein the thermally conductive layer includes metalfoil.
 9. The system of claim 7, wherein the thermally conductive layerincludes metal braid.
 10. The system of claim 7, wherein the thermallyconductive layer includes copper braid.
 11. The system of claim 7,further comprising a thermally conductive housing that at leastpartially encloses and is in thermally conductive contact with theheat-producing electronic module.
 12. The system of claim 11, whereinthe thermally conductive housing is constructed from sheet metal. 13.The system of claim 11, further comprising a heat sink in thermallyconductive contact with the thermally conductive housing and that isconfigured to dissipate heat from the heat-producing electronic module.14. The system of claim 7, further comprising a second thermallyconductive electrical cord attached to the heat-producing electronicmodule. 15-20. (canceled)